Most PPAP rejections come from a handful of avoidable gaps: dimensional results that do not match the print, an incomplete or unsigned PSW, capability studies that miss the required Cpk, or missing supporting documents like the control plan, PFMEA, or MSA. The fix is almost always about completeness and traceability, not about the part itself. Below are the rejections we see most often on Kentucky Truck Plant work and how to clear each one.
Dimensional and print mismatches
The number one rejection is a dimensional layout that does not fully match the ballooned print, or measurements taken from parts that are not from a significant production run. Fix it by ballooning every characteristic, measuring parts made at production rate with production tooling, and flagging any deviation with an approved deviation request rather than leaving it blank. A single unaddressed characteristic can hold the whole submission.
If a feature genuinely cannot meet print yet, do not hide it. Submit an interim approval with a containment plan and a dated corrective action, which the customer can accept while you close the gap.
Incomplete package: PSW, control plan, PFMEA, MSA
PPAP is graded on the whole package, not just the part. A signed Part Submission Warrant, a control plan that matches the PFMEA, capability studies that hit the required Cpk on critical characteristics, and a measurement systems analysis that proves your gauges are capable are all commonly missing or inconsistent with each other. Reviewers reject when the documents contradict one another, so cross-check that the same characteristics, controls, and reaction plans appear consistently across every document.
How to clear a rejection fast
Read the rejection notes literally and answer each one in the resubmission with evidence, not explanation. Rebuild only the sections called out, keep the revision history clean, and have a second set of eyes review the package against the customer checklist before you resubmit. If launch timing is tight, an independent quality engineer can audit your package and run the containment that lets you keep shipping under interim approval while the full PPAP is corrected.